This procedure drains and refills the rear differential fluid on a 2015-2020 Ford F-150 with 5.0L V8 engine and rear-wheel drive configuration.

Warnings

Tools required

Parts

• Differential cover gasket or RTV sealant × 1 — Motorcraft TA-357 RTV or OEM gasket
• Crush washer for fill plug × 1 — Use OEM specification

Fluids

• Motorcraft 75W-140 Synthetic Gear Oil — 2.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Allow differential to cool if vehicle was recently driven
3. Raise rear of vehicle and secure on jack stands at frame contact points
4. Verify vehicle is stable and level before proceeding
5. Position drain pan beneath rear differential

Procedure

1. 1

   Locate fill plug and verify accessibility
   Locate the fill plug on the front face of the differential housing. Remove the fill plug first using a 10mm socket to ensure you can refill the differential before draining. This prevents being unable to refill if the fill plug is seized.
   Torque spec

   Fill Plug51 Nm (38 lb-ft)
2. 2

   Remove fill plug and inspect
   Remove the fill plug completely and inspect the condition. Check for metal shavings on the magnetic tip (minor amount is normal). Set aside with the old crush washer removed. Install new crush washer on fill plug for reinstallation.
3. 3

   Remove differential cover bolts
   Using a 10mm socket, loosen all differential cover bolts in a crisscross pattern. Remove all bolts except the top two, then loosen the top bolts but leave them partially threaded. This allows fluid to drain while keeping the cover from falling.
   ⚠Fluid will begin draining as bolts are loosened. Keep drain pan positioned properly.
   Torque spec

   Cover Bolts42 Nm (31 lb-ft)
4. 4

   Remove cover and drain fluid
   Carefully pry the differential cover loose at the bottom while supporting it. Allow fluid to drain completely into the drain pan. Once drained, remove the top two bolts and remove the cover completely. Be prepared for additional fluid drainage.
5. 5

   Clean differential cover and housing
   Remove all old gasket material or RTV sealant from both the differential cover and housing mating surface using a razor blade or gasket scraper. Clean surfaces thoroughly with brake cleaner and clean rags. Ensure no debris falls into the differential housing. Wipe the interior housing opening clean with a rag.
6. 6

   Apply RTV sealant to cover
   Apply a continuous 3-4mm bead of RTV sealant to the differential cover mating surface. Circle each bolt hole on the outside. Complete the bead within 10 minutes of application and install cover before sealant skins over (typically 15 minutes).
   ℹ️Some F-150 models use a reusable gasket instead of RTV. If a gasket was present, replace with new OEM gasket and do not use RTV.
7. 7

   Install differential cover
   Carefully position the differential cover onto the housing, aligning all bolt holes. Start all cover bolts by hand to ensure proper threading. Do not force any bolts.
8. 8

   Torque differential cover bolts
   Tighten all differential cover bolts in a crisscross pattern to 35 Nm (26 lb-ft) using a torque wrench. Start from the center and work outward. Make multiple passes, gradually increasing torque to avoid warping the cover.
   Torque spec

   Cover Bolts42 Nm (31 lb-ft)
9. 9

   Refill differential with gear oil
   Using a fluid pump, inject Motorcraft 75W-140 Synthetic Gear Oil through the fill plug hole until fluid begins to trickle out of the fill hole. The differential is full when fluid reaches the bottom of the fill plug threads. Approximately 2.0-2.5 quarts will be required.
10. 10

    Install fill plug
    Install the fill plug with new crush washer and tighten to 51 Nm (38 lb-ft) using a torque wrench. Wipe away any spilled gear oil from the differential housing.
    Torque spec

    Fill Plug51 Nm (38 lb-ft)
11. 11

    Inspect for leaks
    Inspect the differential cover and fill plug for any signs of leakage. Wipe the area clean and observe for several minutes. If using RTV sealant, allow recommended cure time (typically 1 hour before operation, 24 hours for full cure) before driving.

Reassembly

1. Lower vehicle from jack stands
2. Dispose of used gear oil properly at a recycling center or auto parts store
3. Clean all tools and work area

Verification

• Start vehicle and drive forward and reverse several feet to circulate new fluid
• Re-inspect differential cover and fill plug for leaks after short test drive
• Check fluid level at fill plug after 24 hours and top off if necessary
• Monitor for leaks after first 100 miles of driving

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